I've had a leak on the throttle shaft on the 300tdi for ages.

Yesterday I went to local diesel specialist and he checks shaft and says there is no play so prob doesn't need new bush ... just new o ring.

So I buy o ring for 60p and a new gasket.

I follow the guide on lr4x4 site. Difference is mine has the egr unit on top of ve pump so has longer shaft. I remove that and take photos of line up of shaft.

Strip top off, push shaft through and replace o ring.

Getting shaft back in and top back on was a little fiddly but got there. Everything back to where it was. Car started straight away but ticked over really roughly and just wouldn't rev.

I've found the prob and it's not great news.

The acc shaft spindle has a sort of horse shoe shaped part underneath ( like a long u shape ). This holds the rod with the governor springs on.
One of the prongs of that horse shoe part has broke off. I suppose I can get a replacement shaft spindle and new horseshoe complete.

... but this broken off bit will be lurking in the pump somewhere. I don't like the sound of that.

So is this a pump off and strip and find that?

That turns a simple job into a massive job.

Bugger!

Bugger indeed.

Gravity has been my enemy so far as the prong has disappeared off to the bottom of the pump so I can't find or see it to retrieve it.

Do I risk gravity being my friend and keeping it there and I just fit a new one ... or do I need to get that out ... which I can only see being a pump off. Will it come out then or will pump have to be stripped?

Bugger again

Get another good pump from the scrapyard/ebay???

Bugger bugger!

Drained fuel out and I could see the broken off part under the governor assembly. Got it out with tweezers.

Ordered a new acc. shaft from local diesel specialists. It arrived this morning so off I set to fetch on the bus ... it's 2 towns away. I get there and the guy hands it to me. I ask him if he's having a laugh as it's the same as the broken one I have at home. He says it has broken in transit and he will have to order me another. Might be here tomorrow.

Unbelievable.

Now then .... this is 300tdi and I'm going to remove the egr anyway. So I will blank off the manifold and fit a 200tdi pipe.

Can I just fit a 200tdi acc shaft/spindle on the fuel pump. They have those in. The difference is just the length of the threaded top on the shaft. Longer on the 300tdi to take the egr sensor on there.

So can I just fit a short threaded 200tdi shaft and tie up the egr sensor. It appears you have to leave the sensor connected to the loom as if you disconnect there the heater plug light doesn't come on when you start car ... but I can't see a prob with just leaving the sensor off the top of the acc shaft and tying it up.

Nobody?